Integrated simulation of CFRTP thermo-stamping process chain and experimental validation

The thermo-stamping process of CFRTP has been widely used in aerospace and automotive applications. However, unreasonable process parameters can cause defects which affect the mechanical properties and assemblability of the workpiece. In this paper, an integrated simulation method for the CFRTP thermo-stamping process chain (including forming-cooling-demolding stage) is proposed, which tries to convey more forming history variables than the traditional method, and aims to accurately predict the forming defects and springback deformation. In detail, the material models used in the different stages are calibrated based on the material data obtained from the experiments, and non-isothermal simulations of the forming stage are performed to predict the relevant defects and to obtain information on the stress, temperature, and thickness of the workpiece after forming. Then, an cooling simulation model was constructed using the history information of the forming stage as the initial condition to obtain the molding results of the workpiece at the end of the cooling stage. Finally, the results obtained during the cooling phase are used to predict the springback of the part after demolding. The simulation method was validated by experiments on hat-shaped beam. The results show that the integrated simulation method of CFRTP process chain can accurately predict the forming results such as fiber shear angle distribution, thickness change, and springback deformation of hat-shaped beams, in which the error of the predicted value of shear angle is 4.08%, the error of the predicted value of thickness is 7.11%. The error of the predicted value of springback is 5.71%.